Wall fabrication system and method

ABSTRACT

A wall fabrication system and method is provided. In an embodiment, an assembly line comprises one or framing stations and one or more insulation stations. The frame stations are configured to build a wall frame consisting of wall studs and a covering such as drywall. The wall studs and drywall define cavities in the frame which are to be insulated. Optionally, mechanical components such as electrical and plumbing can be installed. The wall section is then transferred to the insulation station. The insulation station is configured to fill the cavities in the wall frame with closed cell foam which is injected in flowable form into each cavity.

CROSS-REFERENCE TO RELATED APPLICATION

Applicants claim priority of Canadian Application, Ser. No. 2,573,687,filed Jan. 11, 2007.

FIELD OF THE INVENTION

The present invention relates generally to building construction and inparticular to a wall fabrication system and method.

BACKGROUND OF THE INVENTION

Housing is a critical aspect of social living. The construction ofhouses and other dwellings is therefore a well-known and highly refinedart. Construction techniques and esthetic styles are well known forsingle family dwellings, detached and semi-detached houses,condominiums, apartment buildings, town houses, and the like.

Automation is also broad reaching and used heavily in a broad range ofindustries and is used to build cars, trucks, planes, electronics,appliances and many other products. Automation techniques areincreasingly being applied to the housing industry, and indeed are usedheavily in the manufacture of modular and panelized homes. Automation isnot yet, however, widely applied to the manufacture of traditionalsite-built homes.

When insulating walls in traditional site-built homes, it is common toemploy skilled labourers to stuff bats of fiberglass insulation withinthe cavities defined by wall studs. However, it can be difficult toproperly fill the cavity, and the fiberglass bats can be prone tosagging so that the upper portions of the wall are not properlyinsulated. Likewise, not all cavities have uniform shapes and so thebats need to be cut to size, leaving the possibility for gaps. Anotherdisadvantage with fiberglass insulation is that a properly placed vapourbarrier is also required. Such a vapour barrier is usually provided viaplastic sheets that are applied to the interior side face of the wall.The vapour barrier can be difficult to install, and in any eventpresents extra cost and time in the home construction process. Anotherproblem with vapour barriers is that mould growth and air leakage canresult from punctures that can easily occur in the plastic sheets. Also,application of a moisture barrier in a damp area could actually trapexisting moisture within the wall, particularly where the plasticsheeting becomes wrinkled, with all the attendant problems thereto.

Another common type of insulation is closed cell foam. Closed cell foamcan be acquired in rigid sheets, and thus are not prone to sag in thesame manner as fiberglass. However, the sheets of foam still need to becut to size in order to fill irregular shaped cavities. Also, a vapourbarrier can still be preferred when using sheets of closed cell foam.

It is also known to spray closed cell foam in a liquid form into thewall cavities. A spray gun can be used to fill the cavity with theclosed cell foam, which then cures and forms an insulating barrier.However, this reintroduces a version of the sagging problem withfiberglass insulation, as the liquid insulation tends to flow downwardsin the wall cavity, resulting in an uneven distribution of theinsulation within the wall cavity. Overspray is also a seriousproblem—should the foam be applied to the studs, it can be difficult toattach drywall or other paneling or covering to the wall. Labourersspraying closed cell foam are also exposed to significant environmentalhazards and are preferably equipped with gear to reduce inhalation ofharmful fumes from spraying closed of cell foams.

SUMMARY OF THE INVENTION

In an aspect of the invention there is provided a wall sectioncomprising a first set of substantially parallel supports and a secondset of substantially parallel supports disposed substantiallyperpendicular to the first set. The parallel sets of supports areaffixed to each other at their junctions. The wall section alsocomprises a covering applied to one side of the supports. The coveringand the sets of supports define a plurality of cavities in the wallsection. The wall section also comprises a curable, flowable materialthat is downwardly injected into one or more of the cavities while thesupports are in a horizontal position. Once the material is cured, thewall section can then be moved to the construction site and used tofabricate a home.

The wall section can further comprise a second covering that is appliedto a second side of the supports that is opposite to the first side ofthe supports.

The foam material can adhere to both the first covering and the supportsin such a manner that the covering is adhered to the supports by thefoam material.

The covering can be drywall, or wood sheathing, or any other type ofwall paneling.

The supports can be made from wood or metal or any other suitablematerial.

Depending on the choice of flowable material, when the flowable materialcures into a solid form, a torsional and tensional rigidity of the wallsection can be increased thereby.

Depending on the choice of flowable material, when the flowable materialcures the insulation factor of the wall section can be increasedthereby. The thermal resistance (or R value) per inch of flowablematerial typically surpasses the R value per inch of traditionalfiberglass bats. For example, a traditional bat of 3.5 inch fiberglasshas an R value of about 12, whereas three inches of closed foam has an Rvalue of about eighteen. In general terms, traditional fibreglass batshave an R value of about 3.4 per inch of fiberglass, whereas closed cellfoam has an R value of about six per inch.

Depending on the choice of flowable material, when the flowable materialcures it can provide an air barrier from one side of the wall section tothe other side of the wall section. Furthermore, the flowable materialcan be chosen to have a low vapour permeance, and, when coupled with avapour-barrier primer (applied as a paint to the drywall), then a vapourbarrier can be formed that is suitable to substantially eliminate theneed for plastic sheeting as a vapour barrier.

The flowable material can be closed cell foam. Closed cell foam canresult in increased strength, increased insulation (thermal resistance),and act as an air barrier and has a low vapour permeance.

In other aspects, the flowable material can be open cell foam.

Another aspect of the invention provides a method of insulating a wallsection of a site-built home. The wall section comprises a first set ofsubstantially parallel supports and a second set of substantiallyparallel supports that are disposed substantially perpendicular to thefirst set. The parallel and vertical supports are affixed to each otherat their junctions. The wall section also comprises a coveringpositioned on one side of the supports. The covering and the sets ofsupports define cavities in the wall section. The method comprises:

orienting the wall section horizontally such that the cavities faceupwards; and,

injecting a curable flowable material downwardly into one or more of thecavities.

The method can further comprise applying a second covering to a secondside of the supports that is opposite to the first side of the supports.

The method can further comprise applying the flowable material to boththe first covering and portions of the supports that are perpendicularto the first covering and waiting until the foam material cures suchthat the covering is adhered to the supports.

Another aspect of the invention provides a system for manufacturing awall section comprising one or more framing stations for producing wallsections. The wall sections comprise a first set of substantiallyparallel supports and a second set of substantially parallel supportsdisposed substantially perpendicular to the first set of supports. Thewall sections include a covering applied to one side of the supports.The covering and the sets of supports each define cavities in each wallsection.

The system can also comprise one or more insulation stations forreceiving wall sections from the framing stations and for injecting acurable flowable material downwardly into one or more of the cavitieswhile the supports are in a horizontal position.

The framing stations and the insulation stations can be configured toproduce and insulate, respectively, wall sections that have differentconfigurations.

The system can further comprise automation equipment, such as roboticequipment, for the framing stations and the insulation stations.

The system can further comprise a computer configured to control theautomation equipment in the framing stations and the insulation stationsaccording to a production schedule in order to continuously produce andinsulate a plurality of wall sections having different configurations.

A wall fabrication system and method is provided. In an aspect, anassembly line comprises one or more framing stations and one or moreinsulation stations. The framing stations are configured to build a wallframe consisting of wall studs and a covering such as drywall. The wallstuds and drywall define cavities in the frame which are to beinsulated. Optionally, mechanical components such as electrical,plumbing, central vacuum, telephone and the like can be installed intothe wall section. The wall section is then transferred to the insulationstation. The insulation station is configured to fill the cavities inthe wall frame with closed cell foam which is injected in flowable forminto each cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example only, withreference to certain embodiments and the attached Figures in which:

FIG. 1 is an isometric view of a wall section;

FIG. 2 is a schematic representation of an assembly line formanufacturing and insulating the wall section of FIG. 1;

FIG. 3 is an isometric view of the insulation station of the assemblyline of FIG. 2;

FIG. 4 shows the insulation station of FIG. 3 in greater detail;

FIG. 5 is a partial cross section showing a wall cavity being filledusing the injector of the insulation station of FIG. 3;

FIG. 6 shows the wall section of FIG. 3 after having been filled by theinsulation station of FIG. 3;

FIG. 7 is a partial sectional view of the wall section in FIG. 6 with asecond sheet of drywall being applied thereto; and,

FIG. 8 is a partial sectional view of the wall section of FIG. 6 afterthe second sheet of drywall has been attached thereto.

FIG. 9 shows a variation on the wall section of FIG. 6.

FIG. 10 shows the wall section of FIG. 9 with various programmingparameters identified thereon.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring now to FIG. 1, a wall section for a traditional site-builthome is indicated generally at 50. Wall section 50 comprises a pluralityof substantially parallel vertical studs 54 transversely affixed to aplurality of substantially parallel horizontal studs 58. Not allvertical studs 54 and horizontal studs 58 are labeled in FIG. 1. Studs54, 58 define a frame 60 that is covered on one side by drywall 62 orother type of covering such as plywood, wood or the like. Studs 54, 58act as supports for wall section 50.

It should be understood that terms such as “horizontal” and “vertical”are used for convenience to assist in understanding the discussionherein, but do not imply herein that studs of a frame need to bearranged in such a manner.

Studs 54, 58 can be wood and/or metal and/or any other suitable type ofhome framing material for a traditional site-built home. Studs 54, 58are affixed to each other using nails, staples and/or any other type ofsuitable fastener. Drywall 62 (typically a plurality of sheets ofdrywall) is affixed to frame 60 with nails, staples, screw and/or glueor any other type of suitable fastener. As will be discussed in greaterdetail below, drywall 62 can be only partially affixed to frame 60, sothat drywall 62 is secured to frame 60 so as to simply hold drywall 62in place so that wall section 50 can be further processed, but notsecured to the extent that would traditionally be needed to fully securedrywall 62 to frame 60 in final installation on site. For example, theOntario Building Code 1977 states that “Spacing of ⅝″ long steel drillscrews shall be not more than 300 mm along supports, except that onvertical surfaces the screws may be spaced at 400 mm where the supportsare no more than 400 mm o/c.” The teachings herein can obviatetraditional fasteners and/or mitigate the number of screws that arerequired according to the Ontario Building Code.

Wall section 50 is thus characterized by a plurality of cavities 64-1,64-2, 64-3 . . . 64-9. (Generically, cavity 64, and collectively,cavities 64). Wall section 50, in a present embodiment, is alsocharacterized by a door 68, and a window 70.

It should be understood that the size of wall section 50, theconfiguration, placement and number of studs 54, 58, and theconfiguration, placement and number of cavities, and the configuration,placement and number of cavities of doors or windows (if any) therein isnot particularly limited. While not shown in FIG. 1, it is alsocontemplated that each wall section 50 will also include all mechanicalcomponents, including, for example electrical, plumbing, heatingventilation air-conditioning (“HVAC”) conduits, central vacuum conduits,telephone, cable television, and/or Ethernet and/or outlets relating toany of the foregoing.

Referring now to FIG. 2, wall section 50, in its entirety, is typicallyconstructed on an assembly line 74 in a manufacturing facility. Anexample of such a manufacturing facility described in Applicant'sco-pending application entitled Housing Manufacturing System and Methodand filed in the Canadian Patent Office on Oct. 11, 2006 and bearingapplication number 2,563,187, the contents of which are incorporatedherein by reference.

Assembly line 74 thus includes one or more framing station(s) 78 and oneor more insulation station(s) 82. Insulation station 82 will bediscussed in greater detail below. Framing station 78 is configured toproduce wall section 50. It is also contemplated that assembly line 74is “flexible”, so that while framing station 78 is configured to producewall section 50, framing station 78 is also configured to produce wallsections that have configurations that are different than wall section50. In other words, various wall sections produced on assembly line 74can be different, according to a desired production run for differentconfigurations of traditional site-built homes. Assembly line 74 canalso be fully or partially automated, with computers instructing roboticequipment to manufacture each wall section. In a presently preferredembodiment, assembly line 74 is substantially automated, including thetransfer of wall sections from station 78 to station 82. Thus, assemblyline 74 includes a central scheduling computer 86 that maintains aproduction schedule 90 with production runs for station 78 and station82. Production schedule 90 thus includes instructions for theconfiguration of wall section 50 and configurations for every other wallsection that is to be produced using framing station 78 and insulated atinsulation station 82. Computer 86 is configured to deliver instructionsto operators and/or robotic equipment in framing station 78 as to theconfiguration of each wall section to be produced. Computer 86 is alsoconfigured to notify insulation station 82 as to the configuration ofeach wall section 78 that has been produced so that insulation station82 can fulfill the insulation task.

Referring to FIG. 3, insulation station 82 is shown in greater detail,which shows wall section 50 within station 82. In FIG. 3, insulationstation 82 includes a robotic X-Y Gantry 91. Gantry 91 includes a pairof rails 94. A transverse rail 98 is positioned perpendicular to rails94. Transverse rail 98 is motorized and configured to run along thelength of rails 94. An injector 102 is mounted to transverse rail 98 andis movable along the length of rail 98. A computerized controller 106 isconnected to gantry 91 and can issue instructions thereto in order tomove injector 102 to any location above wall section 50. While thepresent embodiment contemplates a gantry 91, it should be understoodthat other robotic configurations are also contemplated.

Controller 106 is in turn connected to computer 86 and is configured toreceive instructions from computer 86 as to the configuration of theparticular wall section 50 within station 82 as found on productionschedule 90.

Injector 102 is configured to dispense closed cell foam 110 in aflowable form into each cavity 64. Injector 102 is connected to areservoir (not shown) of foam that is located proximal to station 82. Ina presently preferred embodiment, rails 94 and 98 are substantiallyhorizontal and wall section 50 is also positioned substantiallyhorizontally, so that injector 102 is above wall section 102 and allfoam 110 dispensed from injector 102 flows substantially downwardly.

Controller 106 is thus configured to instruct gantry 91 so as to moveinjector 102 above the extent of each cavity 64, and to issueinstructions to a valve associated with injector 102 that causesinjector 102 to either dispense foam 110, or to cause injector 102 to“shut off” and not dispense foam. The valve can also be variable so thatthe rate of flow of foam 110 is variable. Whether injector 102 isdispensing foam or not, injector 102 is movable along rails 94, 98according to instructions from controller 106.

Referring now to FIG. 4, a second wall section 50 a located withinstation 82, while being filled with foam 110 by injector 102, is shownin greater detail. Wall section 50 a includes cavities 64 a and a window70 a. Wall section 50 a is also shown with mechanical components, in theform of electrical conduit 114 a run within cavities 64 a-6, 64 a-7 and64 a-8.

In a presently preferred embodiment, controller 106 is preprogrammedwith a plurality of paths to follow in order to fill each cavity 64.Controller 106 is preprogrammed to move injector 102 within each cavity64 a according to each predefined path, and dispense a bead of foam 110along that path. Controller 106 is also preprogrammed to move injector102 between each cavity 64 a without dispensing any foam. The rate oftravel of injector 102, and flow rate of foam 110 can be chosen in orderto optimize speed of filling each cavity 64, reduce and/or minimize theoverall amount of travel of injector 102 within each cavity 64 a and/orreduce and/or minimize the amount of travel of injector 102 between eachcavity 64 a where injector 102 is not dispensing any foam. In additionto the foregoing, however, the size of the bead that is injected ischosen so as to optimize any settling and/or expansion that may occurwithin each cavity 64 a and the cure times of the foam. It can bedesired to control the manufacturing steps for each station 78 and 82such that the cycle time for each station 78 and 82 are substantiallythe same, and thus the operation of injector 102 can be configuredaccordingly.

Referring now to FIG. 5, for further control over-filling of cavities 64a, it can also be desired to configure injector 102 to be movable alongan axis perpendicular to rail 98, in order to control the depth of foam110. In a present embodiment, however, as best seen in FIGS. 7 and 8,the depth of foam 110 for each cavity is chosen so as to be slightlyless than the depth of studs 54, 58. The actual depth of foam that isdispensed may be less than the final fill depth, in order to account forany expansion of foam that can occur during the curing process.

Referring now to FIG. 6, wall section 50 a is shown having cavities 64 atherein completely filled with foam 110 by a plurality of beads 122 offoam 110. It will be noted that the pattern of fill for each cavity 64 ais unique to that cavity. Table I provides an exemplary summary of eachpattern of fill.

TABLE I Cavity Cavity Description Bead Sequence Bead Description 64a-1  8 feet × 1.5 feet 122-1 1 Runs lengthwise, filling one-third of widthof cavity 64a 64a-1   8 feet × 1.5 feet 122-2 2 Runs lengthwise, fillingone-third of width of cavity 64a 64a-1   8 feet × 1.5 feet 122-3 3 Runslengthwise, filling one-third of width of cavity 64a 64a-2 0.5 feet ×0.9 feet 122-13 19 Runs along width of cavity 64a-2 64a-3 0.5 feet × 0.9feet 122-14 18 Runs along width of cavity 64a-3 64a-4 0.5 feet × 0.9feet 122-15 17 Runs along width of cavity 64a-3 64a-5 0.5 feet × 2.7feet 122-4 4 Runs lengthwise, filling one half of width of cavity 64a-564a-5 0.5 feet × 2.7 feet 122-5 5 Runs lengthwise, filling one half ofwidth of cavity 64a-5 64a-6 0.5 feet × 2.7 feet 122-6 6 Runs lengthwise,filling one half of width of cavity 64a-6 64a-6 0.5 feet × 2.7 feet122-7 7 Runs lengthwise, filling one half of width of cavity 64a-6 64a-70.5 feet × 2.7 feet 122-8 18 Runs along width, filling one third ofcavity 64a-7 64a-7 0.5 feet × 2.7 feet 122-9 9 Runs along width,omitting fill for location of electrical outlet 64a-7 0.5 feet × 2.7feet 122-10 10 Runs along width of cavity 64a-7 64a-8   8 feet × 1 foot122-11 11 Runs ⅔ of length and filling one- third of width of cavity64a-8 64a-8   8 feet × 1 foot 122-12 12 Runs ⅔ of length and fillingone- third of width of cavity 64a-8 64a-8   8 feet × 1 foot 122-18 13Runs along width between other beads and omitting fill for location ofelectrical outlet 64a-8   8 feet × 1 foot 122-19 14 Runs along widthbetween other beads and omitting fill along path of electrical conduit64a-9   8 feet × 1 foot 122-16 16 Runs remainder of length and fillingone-third of width of cavity 64a-8 64a-9   8 feet × 1 foot 122-17 15Runs remainder of length and filling one-third of width of cavity 64a-8

The contents of Table I can thus be converted into programminginstructions for controller 106, with each cavity 64 a being filled byinjector 102 in the order according the sequence in Table I.

Referring now to FIGS. 7 and 8, once wall section 50 has been filledwith insulating foam 110, a second covering can be affixed to frame 60.In a present embodiment the second covering is in the form of drywall126. FIG. 8 in particular shows that the depth of foam is such that asmall gap exists between foam 110 and drywall 126.

However, there is no gap between foam 110 and drywall 62. Thisunderscores one of the advantages of the present invention, as foam 110adheres to drywall 62, thereby affixing drywall 62 to frame 60 in amanner that can be more secure than at least some prior art methodswhich include the sole use of nails and/or staples and/or glue. Sincethe use of mechanical fasteners (e.g. nails and/or staples) can besubstantially eliminated, or at least reduced, drywall 62 is much lesssusceptible to the phenomenon of “nail-pops” whereby drywall nails, overtime, appear to be driven out of wooden studs 54, 58 and protrude fromthe surface of drywall 62, with an unsightly effect. This annoyingphenomenon can be common on traditional wooden wall panels, as moistureevaporates from studs 54, 58 and giving the appearance of pushing thenails out of the wood frame as the wood shrinks away from the frame. Itcan be one of the most significant causes of warranty claims on newhomes and therefore it is strongly desirable to obviate nail-pops.

Also, as another advantage, since cavities 64 are filled while wallsection 50 is horizontal, the depth of foam 110 is substantiallyuniform. Likewise the insulating properties are also substantiallyuniform along the length of wall section 50. Likewise, the mechanicaladherence of drywall 62 to frame 60 is substantially uniform throughoutthe entire extent of drywall 62.

Also, as another advantage, the substantially uniform fill of each wallsection 50 can obviate the need for a traditional vapour-barrier ofplastic sheeting to be applied, particularly when a vapour-barrierprimer is applied to the wall section 50.

Also, as another advantage, the filling of each wall section 50 withfoam 110 can increase the overall strength, both in torsion and intension, of each wall section 50. As a result, when wall sections aremanufactured in a facility for shipping to the construction site, wallsections manufactured according to the teachings herein are moreresilient during the shipping process and less susceptible to damagethan traditional, prior art wall sections.

It is believed that the teachings herein can, in certain applications,obviate the use of fasteners for drywall 62 to stud 58 altogether, asthe adhesion between the foam and the drywall 62 and stud 58 issufficient. Also the use of closed cell foam, can permit the reductionin the thickness of an exterior wall cavity from six inches to fourinches, since the closed cell foam has an R value per inch that isgreater than the R value per inch of traditional fiberglass insulationbats. This reduction in wall cavity thickness reduces the amount oflumber used and reduces stresses on the environment. Thus, a four inchwall cavity using the teachings herein can have the same, or better,air-conditioning and heating costs as a six inch wall cavity thatemploys traditional fiberglass bats. As a still further advantage, anengineered ventilated station can be configured to thereby reduceexposure to fumes given off during application. When foam is sprayedvertically into wall cavities on a construction site, the operator hasto wear ventilation gear, yet an engineered ventilation system can meanthat the operator need wear no gear when foam is sprayed using theteachings herein. Further, in a factory environment as described herein,the option exists to substantially completely recover the gases andprevent them from release into environment, and there by substantiallyreduce off-gassing into the environment.

Referring now to FIGS. 9 and 10, a variation on wall section 50 a isindicated as wall section 50 b. FIGS. 9 and 10 show the specificsequence of passes for each cavity of wall section 50 b. Appendix Ihereto describes the application parameters of foam for each cavity ofwall section 50 b.

The present invention thus provides, amongst other things, a novelsystem and method for manufacturing wall sections of houses by providingan assembly line for producing and insulating wall sections.

While the foregoing describes certain specific embodiments of thepresent invention, it should be understood that variations, combinationsand sub-sets of those embodiments are contemplated.

1. A wall section comprising: a first set of substantially parallelsupports; a second set of substantially parallel supports disposedsubstantially perpendicular to said first set; a covering applied to oneside of said supports; said covering and said sets of supports definingcavities; and, a curable flowable material downwardly injected into oneor more of said cavities while said supports are in a horizontalposition.
 2. The wall section of claim 1 further comprising a secondcovering applied to a second side of said supports that is opposite tosaid first side of said supports.
 3. The wall section of claim 1 whereinsaid foam material adheres to both said first covering and said supportssuch that said covering is adhered to said supports by said foammaterial.
 4. The wall section of claim 1 wherein said covering isdrywall.
 5. The wall section of claim 1 wherein said supports are madefrom wood.
 6. The wall section of claim 1 wherein said supports are madefrom metal.
 7. The wall section of claim 1 wherein said flowablematerial is closed cell foam.
 8. The wall section of claim 1 whereinwhen said flowable material cures a torsional and tensional rigidity ofsaid wall section is increased thereby.
 9. The wall section of claim 1wherein when said flowable material increases the insulation factor ofsaid wall section.
 10. The wall section of claim 1 wherein when saidflowable material provides at least a partial vapour barrier from oneside of said wall section to the other side of said wall section.
 11. Amethod of insulating a wall section of a site-built home; said wallsection comprising a first set of substantially parallel supports; asecond set of substantially parallel supports disposed substantiallyperpendicular to said first set; a covering positioned on one side ofsaid supports; said covering and said sets of supports definingcavities; the method comprising: orienting said wall sectionhorizontally such that said cavities face upwards; and, injectingcurable flowable material downwardly into one or more of said cavities.12. The method of claim 11 wherein further comprising applying a secondcovering to a second side of said supports that is opposite to saidfirst side of said supports.
 13. The method of claim 11 wherein saidfoam material is applied to both said first covering and portions ofsaid supports that are perpendicular to said first covering and furthercomprising the step of: waiting until said foam material cures such thatsaid covering is adhered to said supports.
 14. The method of claim 11wherein said covering is drywall.
 15. The method of claim 11 whereinsaid supports are made from wood.
 16. The method of claim 11 whereinsaid supports are made from metal.
 17. The method of claim 11 whereinsaid curable material is closed cell foam.
 18. The method of claim 11wherein when said curable flowable material is selected such that whensaid flowable material cures a torsional and tensional rigidity of saidwall section is increased thereby.
 19. The method of claim 11 whereinsaid curable flowable material is selected such that when said flowablematerial cures said material increases the insulation factor of saidwall section.
 20. The method of claim 11 wherein said curable flowablematerial is selected so as to provide at least a partial vapour barrierfrom one side of said wall section to the other side of said wallsection when said.
 21. A system for manufacturing a wall sectioncomprising: one or more framing stations for producing wall sectionsthat comprise a first set of substantially parallel supports; a secondset of substantially parallel supports disposed substantiallyperpendicular to said first set; a covering applied to one side of saidsupports; said covering and said sets of supports defining cavities; oneor more insulation stations for receiving wall sections from saidframing stations and for injecting a curable flowable materialdownwardly into one or more of said cavities while said supports are ina horizontal position.
 22. The system of claim 21 wherein said framingstations and said insulation stations are configured to produce andinsulate, respectively, wall sections that have differentconfigurations.
 23. The system of claim 22 further comprising automationequipment for said framing stations and said insulation stations. 24.The system of claim 23 further comprising a computer configured tocontrol said automation equipment in said framing stations and saidinsulation stations according to a production schedule in order tocontinuously produce and insulate a plurality of wall sections havingdifferent configurations.
 25. The system of claim 21 wherein saidcovering is an inside wall of a home.
 26. The system of claim 21 whereinsaid covering is an outside wall of a home